Posts for fence systems, fence systems, and methods of assembling and installing the same

ABSTRACT

A post for use in a fence installation is provided. The post includes a body portion defining a first plurality of mortises in a fixed position with respect to the body portion. The post also includes an adjustable portion defining a second plurality of mortises, the adjustable portion being engageable with the body portion such that a position of the second plurality of mortises is adjustable with respect to the body portion.

CROSS REFERENCE TO RELATED APPLICA ON

The application claims the benefit of U.S. Provisional Patent Application No. 62/881,999 filed on Aug. 2, 2019, the contents of which are incorporated herein by reference.

FIELD

The invention relates to fence systems, and more particularly, to improved posts for fence systems, and improved methods of assembling and installing fence systems.

BACKGROUND

Manufacturing and installation of fence systems (e.g., plastic fence systems, composite fence systems, etc.) continues to be labor intensive and time consuming. Particular challenges exist in connection with installation of fence systems when the ground surface is uneven (e.g., a sloped ground surface, etc.).

In such applications, posts included in the fence system are often drilled or otherwise cut at the installation location to compensate for changes in elevation of the ground surface. The time and labor associated with these types of challenges significantly increases the costs of the fence system.

Thus, it would be desirable to provide improved posts, improved fence systems, and improved method of assembling and installing the same.

SUMMARY

According to an exemplary embodiment of the invention, a post for use in a fence installation is provided. The post includes a body portion defining a first plurality of mortises in a fixed position with respect to the body portion. The post also includes an adjustable portion defining a second plurality of mortises. The adjustable portion is engageable with the body portion such that a position of the second plurality of mortises is adjustable with respect to the body portion.

According to another exemplary embodiment of the invention, a fence system is provided. The fence system includes a first post. The first post including (i) a first body portion and (ii) a first adjustable portion defining a plurality of mortises, the first adjustable portion being engageable with the first body portion such that a position of the plurality of mortises, is adjustable with respect to the first body portion. The fence system also includes a second post, and at least one rail configured to be positioned between one of the plurality of mortises and the second post.

According to another exemplary embodiment of the invention, a method of installing a fence system is provided. The method includes the steps of: (a) determining information related to a change in elevation of installation of a first post and a second post; (b) installing the first post, the first post defining a plurality of mortises; (c) installing the second post using the information from step (a), the second post including (i) a second body portion and (ii) a second adjustable portion defining a second plurality of mortises, the second adjustable portion being engageable with the second body portion such that a position of the second plurality of mortises is adjustable with respect to the second body portion; and (d) installing a rail between the first post and the second post, the rail being engaged between (i) one of the plurality of mortises defined by the first post and (ii) one of the second plurality of mortises defined by the second post.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention is best understood from the following detailed description when read in connection with the accompanying drawings. It is emphasized that, according to common practice, the various features of the drawings are not to scale. On the contrary, the dimensions of the various features are arbitrarily expanded or reduced for clarity. Included in the drawings are the following figures:

FIG. 1 is a side view showing a partial internal view of a fence system in accordance with an exemplary embodiment of the invention;

FIGS. 2A-2D are perspective views showing assembly of a first post from the fence system of FIG. 1, in accordance with an exemplary embodiment of the invention;

FIGS. 3A-3D are various views of the first post of FIG. 1 in accordance with an exemplary embodiment of the invention;

FIGS. 4A-4D are side views of a plurality of posts in accordance with various exemplary embodiments of the invention;

FIGS. 5A-5G are top views of a plurality of posts accordance with various exemplary embodiments of the invention

FIGS. 6A-6B and 7A-7D are side views of a plurality of fence systems in accordance with various exemplary embodiments of the invention; and

FIGS. 8A-8C are side views illustrating a method of installing a fence system in accordance with an exemplary embodiment of the invention.

DETAILED DESCRIPTION

As used herein, the terms “first”, “second”, “third”, “fourth”, etc., with with respects to any component (such as posts, mortises, plurality of mortises, rails, etc.) are arbitrary in nature. Thus, a “first” post does not mean it is installed first, or have any other meaning other than as a descriptor in a given example. Further, such descriptors (i.e., first, second, etc.) may be changed herein from one example to another.

Referring now to the drawings, FIG. 1 is a side view of a fence system 100. Fence system 100 includes a first post 110 and a second post 104. An upper rail 106, and a lower rail 108, are provided between first post 110 and second post 104. Additional rails 106, 188 extend toward another post (not shown) to the left of first post 110. Further, additional rails 106, 108 extend toward yet another post (not shown) to the right of second post 104.

First post 110, and second post 104, are installed in the earth 102. As shown in FIG. 1, the ground surface of earth 102 is uneven (e.g., sloped and/or not level). Second post 104 defines two upper mortises 104 a (provided on opposite sides of second post 104), and two lower mortises 104 b (provided on opposite sides of second post 104). These upper mortises 104 a, and lower mortises 104 b, are in a fixed position with respect to second post 104. Upper mortises 104 a receive upper rails 106, and lower mortises 104 b receive lower rails 108.

First post 118 includes a body portion 120 defining a first plurality of mortises (in this example, upper mortise 122 and lower mortise 124) in a fixed position with respect to body portion 120. First post 110 also includes an adjustable portion 130 defining a second plurality of mortises (in this example, upper mortise 132 and lower mortise 134). Upper mortises 122, 132 receive respective upper rails 106. Likewise, lower mortises 124, 134 receive respective lower rails 108.

Adjustable portion 130 is engageable with body portion 120 such that a position of the second plurality of mortises 132, 134 is adjustable with respect to body portion 120. By utilizing adjustable portion 130, first post 110 is able to account for the uneven ground surface of earth 102. This technique is utilized in connected with methods of assembling fence systems in accordance with the invention (such as the method of FIGS. 8A-8C).

FIGS. 2A-2D are perspective views showing assembly of first post 110. FIG. 2A illustrates body portion 120 (e.g., a U shaped channel) separated from adjustable portion 130 (e.g., a panel configured for engagement with body portion 120). In FIG. 2B, adjustable portion 130 is slidably engaged with body portion 120. When adjustable portion 130 is slid to a desired position (e.g., when upper mortise 132 and lower mortise 134 are in a desired position to receive respective rails of the fence system—for example, to account for unlevel earth), a discard portion 136 is cut (or otherwise separated from) adjustable portion 130, as shown in FIG. 2C. Thus, FIG. 2D shows fully assembled first post 110.

FIGS. 3A-3D are additional illustrations of first post 110. FIG. 3A is a side view showing upper mortise 132 and lower mortise 134, of adjustable portion 130. In dotted lines in FIG. 3A, the mortises of body portion 120 are also shown (i.e., see upper mortise 122 and lower mortise 124 shown in FIG. 1). FIG. 3B is a cross section of first post 110 of FIG. 3A, taken along the cross section line shown in FIG. 3A. In FIG. 3B, the sliding engagement of adjustable portion 130 with respect to body portion 120 is illustrated by the up and down arrows. From FIG. 3B (and FIG. 2B), it is clear that adjustable portion 130 is slidably engageable with body portion 120 such that a position of upper mortise 132 and lower mortise 134 is adjustable with respect to body portion 120.

FIG. 3C and FIG. 3D are top views of first post 110. FIG. 3C illustrates body portion 120 and adjustable portion 130 separated from one another. Adjustable portion 130 is configured to be snapped in place with body portion 120. Specifically, body portion 120 defines a groove 126 configured to receive an engagement portion 138 of adjustable portion 130 during engagement therebetween. Likewise, adjustable portion 130 defines a groove 136 configured to receive an engagement portion 128 of body portion 120 during engagement therebetween. In certain embodiments of the invention, when adjustable portion 130 is snapped in place with body portion 120 as shown in FIG. 3D, adjustable portion 130 may slide up and down with respect to body portion 120 (see up and down arrows in FIG. 36, and arrow in FIG. 26).

Of course, the embodiments of the invention shown in FIG. 1, FIGS. 2A-2D, and FIGS. 3A-3D are exemplary in nature. Many variations are contemplated.

For example, FIGS. 4A-4D show examples of adjustable portion 130 (including variations 130 a, 130 b, and 130 c). Of course, other embodiments (not shown in FIGS. 4A-4D) are contemplated within the scope of the invention. FIG. 4A is a side view of a part of adjustable portion 130 defining upper mortise 132 and lower mortise 134 (the same adjustable portion 130 described above with respect to FIGS. 1, 2A-2D, and 3A-3D). FIG. 4B is a side view of a part of a different adjustable portion 130 a defining upper mortise 132 a and lower mortise 134 a—with different shapes as compared to upper mortise mortise 132 and lower mortise 134 of adjustable portion 130. FIG. 4C is a side view of a part of a different adjustable portion 130 b defining upper mortise 132 b, center mortise 132 b 1, and lower mortise 134 b—that is, three mortises compared to the two mortises (i.e., upper mortise 132 and lower mortise 134) of adjustable portion 130. FIG. 4D is a side view of a part of a different adjustable portion 130c defining mortises upper mortise 132 c, second mortise 132 c 1, third mortise 132 c 2, and lower mortise 134 c—that is, four mortises (having round shapes) compared to the two mortises (i.e., upper mortise 132 and lower mortise 134) of adjustable portion 130.

FIGS. 5A-5G show examples of first post 110 (including variations 110 d, 110 e, 110 f, 110 g, 110 h, and 110 i). Of course, other embodiments (not shown in FIGS. 5A-5G) are contemplated within the scope of the invention. FIG. 5A is a top view of post 110 including body portion 120 and adjustable portion 130 (the same post described above with respect to FIGS. 1, 2A-2D, and 3A-3D). FIG. 5B is a top view of a different post 110 d including body portion 120 d (defining groove 126 d, and including engagement portion 128 d) and adjustable portion 130 d (defining groove 136 d, and including engagement portion 138 d) (where each of grooves 126 d receives a corresponding engagement portion 138 d during engagement therebetween) (where each of grooves 136 d receives a corresponding engagement portion 128 d during engagement therebetween). FIG. 5C is a top view of a different post 110e including body portion 120 e (defining groove 126 e) and adjustable portion 130 e (including engagement portion 138 e) (where each groove 126 e receives a corresponding engagement portion 138 e during engagement therebetween). FIG. 5D is a top view of a different post 110 f including body portion 120 f and adjustable portion 130 f (where two butt joints exist between adjustable portion 130 f and body portion 120 f) (where the butt joints may also be miter joints, or other joints). FIG. 5E is a top view of a different post 110 g (having a non-square rectangular area as opposed to the square area of first post 110 in FIG. 5A) including body portion 120 g (defining groove 126 g, and including engagement portion 128 g) and adjustable portion 130 g (defining groove 136 g, and including engagement portion 138 g) (where each of grooves 126 g receives a corresponding engagement portion 138 g during engagement therebetween) (where each of grooves 136 g receives a corresponding engagement portion 128 g during engagement therebetween). FIG. 5F is a top view of a different post 110 h (having a non-square rectangular area as opposed to the square area of first post 110 in FIG. 5A) including body portion 120 h (defining groove 126 h) and adjustable portion 130 h (including engagement portion 138 h) (where each groove 126 h receives a corresponding engagement portion 138 h during engagement therebetween). FIG. 5G is a top view of a different post 110 i (having a round area as opposed to the square area of first post 110 in FIG. 5A) including body portion 120 i and adjustable portion 130 i.

FIGS. 6A-6B illustrate two exemplary fence systems 200, 300. FIGS. 7A-7D illustrate four exemplary fence systems 400, 500, 600, and 700. The reference numerals in FIGS. 6A-6B and FIGS. 7A-7D are similar to numberals used in FIG. 1, FIGS. 2A-2D, and FIGS. 3A-3D (wherein like numerals refer to like elements)—except that in FIG. 6A the reference numerals begin with a “2”, and in FIG. 6B the reference numerals begin with a “3”, and in FIG. 7A the reference numerals begin with a “4”, and in FIG. 7B the reference numerals begin with a “5”, and in FIG. 7C the reference numerals begin with a “6”, and in FIG. 7D the reference numerals begin with a “7”. Details for like elements are not not repeated here for the sake of brevity.

Referring specifically to FIG. 6A, fence system 200 is used in a stepped application (i.e., a fence system along a set of steps, or a stepped grade) in earth 202. Fence system 200 includes a first post 210 between two seconds posts 204. Upper rails 206, and lower rails 208 are provided between first post 210 and a respective one of second posts 204. First post 210 includes body portion 220 and adjustable portion 230. Of course, more first posts and/or second posts be included in fence system 200.

Referring specifically to FIG. 6B, fence system 300 is used in a graded application (i.e., a fence system along an uneven grade) in earth 302. Fence system 300 includes a plurality of first posts 310 between two seconds posts 304. Upper rails 306, and lower rails 308 are provided between respective pairs of posts. Each first post 310 includes a body portion 320 and adjustable portion 330. Of course, more first posts 310 and/or second posts 304 be included in fence system 300, as desired.

Aspects of the invention have been described above largely with respect to fence systems including two simple rails (i.e., an upper rail and a lower rail). However, the invention is not limited thereo. That is, many different types of fence systems may utilize the teachings of the invention. FIGS. 7A-7D illustrate examples of such fence systems. Referring specifically to FIG. 7A, a fence system 400 is illustrated including a pair of posts (where each post could be a first post 410 or a second post 404), and an upper rail 406 and a lower rail 408 provided between the pair of posts. Pickets 412 are provided spanning a gap between upper rail 406 and lower rail 408. Referring specifically to FIG. 7B, a fence system 500 is illustrated including a pair of posts (where each post could be a first post 510 or a second post 504), with upper rail 506 and lower rail 508 provided between the pair of posts. Panel 512 (which may include a single panel piece, or a plurality of pieces forming the panel) is provided spanning a gap between upper rail 506 and lower rail 508. Referring specifically to FIG. 7C, a fence system 600 is illustrated including a pair of posts (where each post could be a first post 610 or a second post 604), upper rail 606, center rail 607, and lower rail 608 provided between the pair of posts. Pickets 612 are provided spanning a gap between upper rail 606 and lower rail 608. Referring specifically to FIG. 70, a fence system 700 is illustrated including a pair of posts (where each post could be a first post 710 or a second post 704). An upper rail 706, a second rail 707 a, a third rail 707 b, and a lower rail 703 are provided between the pair of posts.

Thus, it is clear that in accordance with the invention, fence systems may be provided with any number of posts including the body portion and the adjustable portion described herein, along with any number of conventional posts (where adjustment is not needed, for example, because a span of fencing crosses an area with an acceptable grade). Likewise, any number of mortises may be defined by the posts, as desired in the application. Likewise, any number of rails, and additional fence components (e.g., pickets, panels, etc.) may be provided, as desired in the application.

FIGS. 8A-8C are side views illustrating a method of installing a fence system in earth 102, in accordance with an exemplary embodiment of the invention. The method includes a step of determining information related to a change in elevation of installation of a first post and a second post (see FIG. 1 for illustrations related to height measurements). For example, FIG. 8A illustrates a post 104 defining two upper mortises 104 a and two lower mortises 104 b (see post 104 described in FIG. 1). After installing post 104 (or at another time, perhaps before the installation), grade/angle change information may be taken between the position of post 104 and the position of the to be installed adjustable post 110 (where the adjustable post is not yet installed in FIG. 5A, but the location is identified). This grade/angle change information is an example of information related to a change in elevation of installation of two posts (e.g., post 110 and post 104).

The method also includes the step of installing the post 104, as shown in FIG. 8A. The method also includes installing the post 110 (as shown in FIG. 8B), using the information determined that relates to a change in elevation for installation of the two posts. The post 110 (see post 110 described in FIG. 1) includes a body portion 120, and an adjustable portion 130. The adjustable portion 130 is prepared as desired (e.g., see FIGS. 2A-2D), using the ability to adjust a plurality of mortises 132, 134 of the adjustable portion 130.

The method also includes the step of installing a rail (or a plurality of rails) between post 104 and post 110. For example, FIG. 8C illustrates installation of an upper rail 106 and a lower rail 108 (as well as pickets 112) between post 104 and post 110. Upper rail 106 and lower rail 108 are engaged between (i) one of the plurality of mortises defined by post 104 and (ii) one of the plurality of mortises defined by post 110 (e.g., one of the plurality of mortises defined by the adjustable portion 130 of post 110).

While FIGS. 8A-8C illustrate installation of a specific fence system (including specific posts, and rails) it is exemplary in nature. The methods of the invention may be applied to any fence systems within the scope of the invention (including but not limited to those illustrated and described herein).

Various materials may be used to form posts in accordance with the invention (and if desired, the rails or other portions of a fence system). Such exemplary materials include plastic materials (e.g., PVC—polyvinyl chloride, polyurethane, polypropylene, etc.), composite materials (e.g., wood composite, fiberglass composite, a metal composite), amongst others.

Although aspects of the invention are described with respect to fences and fence systems, it is understood that these terms are intended to be broadly construed and refer to any type of system utilizing the inventive posts. Thus, the term fence (or fence system) shall include traditional lengths of fencing, railings (and railing systems), stair railings, etc.

Although the invention is illustrated and described herein with reference to specific embodiments, the invention is not intended to be limited to the details shown. Rather, various modifications may be made in the details within the scope and range of equivalents of the claims and without departing from the invention. 

What is claimed:
 1. A post for use in a fence installation, the post comprising: a body portion defining a first plurality of mortises in a fixed position with respect to the body portion; and an adjustable portion defining a second plurality of mortises, the adjustable portion being engageable with the body portion such that a position of the second plurality of mortises is adjustable with respect to the body portion.
 2. The post of claim 1 wherein the body portion includes a “U” shaped channel, and wherein the first plurality of mortises are defined by a wall portion of the “U” shaped channel.
 3. The post of claim 1 wherein the adjustable portion is slidably engageable with the body portion such that the position of the second plurality of mortises is adjustable with respect to the body portion.
 4. The post of claim 1 wherein the adjustable portion is configured to be snapped in place with the body portion.
 5. The post of claim 1 wherein the body portion defines a groove configured to receive an engagement portion of the adjustable portion during engagement therebetween.
 6. The post of claim 1 wherein the adjustable portion defines a groove configured to receive an engagement portion of the body portion during engagement therebetween.
 7. The post of claim 1 wherein at least one of a miter joint and a butt joint is provided between the body portion and the adjustable portion during engagement therebetween.
 8. The post of claim 1 wherein each of the body portion and the adjustable portion is formed of a material selected from the group consisting of a plastic material and a composite material.
 9. A fence system comprising: a first post, the first post including (i) a first body portion and (ii) a first adjustable portion defining a plurality of mortises, the first adjustable portion being engageable with the first body portion such that a position of the plurality of mortises is adjustable with respect to the first body portion; second post; and at least one rail configured to be positioned between one of the plurality of mortises and the second post.
 10. The fence system of claim 9 wherein the second post includes (i) a second body portion and (ii) a second adjustable portion defining a second plurality of mortises, the second adjustable portion being engageable with the second body portion such that a position of the second plurality of mortises is adjustable with respect to the second body portion.
 11. The fence system of claim 9 wherein the first body portion defines a third plurality of mortises in a fixed position with respect to the first body portion.
 12. The fence system of claim 10 wherein the first body portion defines a third plurality of mortises in a fixed position with respect to the first body portion.
 13. The fence system of claim 11 wherein the first body portion includes a “U” shaped channel, and wherein the third plurality of mortises are defined by a wall portion of the “U” shaped channel.
 14. The fence system of claim 12 wherein the second body portion defines a fourth plurality of mortises in a fixed position with respect to the first body portion.
 15. The fence system of claim 9 wherein the first adjustable portion is slidably engageable with the first body portion such that the position of the plurality of mortises is adjustable with respect to the first body portion.
 16. The fence system of claim 9 the first adjustable portion is configured to be snapped in place with the first body portion.
 17. A method of installing a fence system, the method comprising the steps of: (a) determining information related to a change in elevation of installation of a first post and a second post; (b) installing the first post, the first post defining a plurality of mortises; (c) installing the second post using the information from step (a), the second post including (i) a second body portion and (ii) a second adjustable portion defining a second plurality of mortises, the second adjustable portion being engageable with the second body portion such that a position of the second plurality of mortises is adjustable with respect to the second body portion; and (d) installing a rail between the first post and the second post, the rail being engaged between (i) one of the plurality of mortises defined by the first post and (ii) one of the second plurality of mortises defined by the second post.
 18. The method of claim 17 installing a second rail between the first post and the second post, the second rail being engaged between (i) another of the plurality of mortises defined by the first post and (ii) another of the second plurality of mortises defined by the second post.
 19. The method of claim 17 wherein the second body portion defines a third plurality of mortises in a fixed position with respect to the body portion.
 20. The method of claim 17 wherein the first post includes (i) a first body portion and (ii) a first adjustable portion, the first adjustable portion being engageable with the first body portion, the plurality of mortises defined by the first post being defined by the first body portion or the first adjustable portion. 